Wheel hub bearing module for a suspension upright or knuckle

Abstract

A hub bearing module for a lightweight suspension upright or knuckle of a vehicle, the hub bearing module including a wheel bearing and a bearing connection interface to the suspension upright or knuckle, the bearing connection interface being arranged coaxial with the rolling bearing and including a first sleeve element and a second sleeve element arranged radially outside the first sleeve element and including a composite, preferably BMC (Bulk Molding Compound) annular body having a radially inner lateral surface mechanically coupled to the first sleeve element and a radially outer lateral surface configured to mechanically and chemically couple with the suspension upright or knuckle.

What is claimed is: 
     
       1. A hub bearing module for a suspension upright or knuckle of a vehicle, the hub bearing module comprising:
 a wheel bearing; and 
 a bearing connection interface arranged coaxial with the wheel bearing and configured to connect the wheel bearing to the suspension upright or knuckle, the bearing connection comprising:
 a first sleeve element; and 
 
 a second sleeve element arranged radially outside the first sleeve element, the second sleeve comprising:
 an annular body having a radially outer lateral surface mechanically coupled to the first sleeve element; 
 a radially inner lateral surface made of a composite material comprising reinforcing fibers dispersed in a polymer matrix, 
 wherein the individual reinforcing fibers form groups of fibers aligned with respect to each other, the groups uniformly dispersed randomly in the polymer matrix; and
 an interface element bonded to the radially outer lateral surface of the annular body and comprising a mat or plies of continuous fibers embedded in a partially cured polymer matrix, wherein the fibers of the mat or plies have a length equal to a length of the interface element and are arranged in a plurality of superimposed layers, 
 
 
 wherein the radially outer lateral surface being configured to mechanically and chemically couple with the suspension upright or knuckle. 
 
     
     
       2. The hub bearing module according to  claim 1 , wherein the composite annular body is partially cured and has been overmolded upon an outer lateral surface of the first sleeve element, the outer lateral surface of the first sleeve element being cylindrical, extending along a first axis of symmetry (A) thereof and being treated to increase adhesion to the composite annular body. 
     
     
       3. The hub bearing module according to  claim 2 , wherein the outer lateral surface of the first sleeve element has been mechanically or chemically worked, creating a surface texture that increases a surface area of the outer lateral surface. 
     
     
       4. The hub bearing module of  claim 3 , wherein the outer lateral surface of the first lateral sleeve is mechanically or chemically worked by knurling or lettering. 
     
     
       5. The hub bearing module according to  claim 2 , wherein the outer lateral surface of the first sleeve element is further provided with locking means embedded in the composite annular body. 
     
     
       6. The hub bearing module according to  claim 5 , wherein the locking means are selected from the group consisting of:
 at least two annular grooves having a circular shape provided axially spaced apart on the outer lateral surface of the first sleeve element; 
 at least two annular grooves having a sinusoidal shape provided on the outer lateral surface of the first sleeve element at an axial distance there between such that they intersect to each other; 
 at least one annular groove provided on the outer lateral surface of the first sleeve element, the annular groove having a circular shape with non-constant cross section, an axial width of the annular groove progressively and alternately widening and narrowing along a tangential development of the annular groove; 
 at least one non-circular, non-annular groove provided on the outer lateral surface of the first sleeve element according to an helicoid path; 
 and 
 at least two annular grooves having a circular shape and provided axially spaced apart on the outer lateral surface of the first sleeve element, each adjacent to a respective opposite end of the first sleeve element, each groove being delimited in an axial direction by one first flank defined by an inclined surface sloping radially outward toward the axial end immediately adjacent thereto and by one second flank, arranged opposite the first and delimited by a flat surface extending radially outwards and arranged substantially perpendicular to the first axis of symmetry. 
 
     
     
       7. The hub bearing module according to  claim 6 , wherein the at least one groove has a radial depth comprised between 0.2 and 5 mm and preferably comprised between 1 and 2 mm. 
     
     
       8. The hub bearing module according to  claim 6 , wherein the locking means comprises a radial cross section defining one or more radially extending undercuts in the groove. 
     
     
       9. The hub bearing module according to  claim 1 , wherein the wheel bearing further comprises:
 an outer ring comprising the first sleeve element and 
 an inner ring arranged coaxial with the outer ring, 
 wherein the first sleeve element is made of bearing grade steel. 
 
     
     
       10. The hub bearing module according to  claim 1 , wherein the composite annular body and the mat or plies are formed by organic or inorganic fibers embedded in a polymer matrix, the fibers in the BJVIC/LFT/DLFT annular body configured to be shorter than those in the mat or plies. 
     
     
       11. The hub bearing module according to  claim 10 , wherein the composite annular body consists of 30-70% by volume of carbon fibers having an average length comprised between 10 mm and 50 mm dispersed in a polymer matrix, the polymer matrix added with a filler and formed by a resin selected from the group consisting in: epoxy, PA6 (polyamide 6), PA66, PA11, PA12, polyphenylene sulfide, PEEK, PAEK, PEKK, or any 20 mixture of the above. 
     
     
       12. The hub bearing module of  claim 1 , wherein the composite material is selected from a group consisting of BMC (Bulk Molding Compound), LFT (Long Fiber Thermoplastic) and DLFT (Direct Long Fiber Thermoplastic).